Air quality monitoring and control system

ABSTRACT

An air quality system includes an air precleaner, a filter identification component, and a control module. The air precleaner has a precleaner housing and a filter disposed inside the precleaner housing. The filter identification component is positioned within the precleaner housing at a first position and is mounted on the filter. The control module is positioned within the precleaner housing at a second position and is configured to emit an electrical field and communicate with the filter identification component via the emitted electrical field.

This application is a Continuation of application Ser. No. 17/092,819filed Nov. 9, 2020, which is a Continuation of application Ser. No.16/022,941 filed Jun. 29, 2018, now U.S. Pat. No. 10,850,222 B2, whichclaims the benefit of priority from Provisional Application No.62/527,276 filed Jun. 30, 2017, the entire contents of the priorapplications being incorporated herein by reference.

BACKGROUND

The present disclosure relates to an air quality monitoring and controlsystem for monitoring and controlling air quality within an enclosure,such as a vehicle cabin.

To maintain air quality inside an enclosure, certain environmentalconditions must be maintained. Conventionally, this has presentedproblems due to the inability to control certain variables such as CO₂concentrations which come from the exhaling operator of, for example, avehicle cabin (also referred to as a “cab”). Fresh air intake and cableakage are additional variables which have been difficult to measureand control. To keep dust out of the cab, the cab must be undercontinuous positive pressurization. This is difficult to achieve in astatic system due to changing variables such as dirt load on an airfilter, operator interface with the HVAC blower motor, open doors andwindows, and dust on the operator vestments brought into the cab.

Prior attempts at addressing these problems are antiquated andinadequate to address the real-world operating conditions ofenvironmental cabs. Currently pressure sensors, pressure switches, andCO₂ sensors are used in cabs. There is currently no integrated proactivecomprehensive cab air quality system.

SUMMARY

Exemplary embodiments of the broad inventive principles described hereinaddress the aforementioned problems by providing a comprehensive cab airquality system that proactively monitors and controls devices within andoutside the cab such as an air precleaner in order to control parameterssuch as airflow, cab pressure, gas concentration, and alarm conditions.

It should be understood that the following disclosure is not limited tomonitoring and controlling air quality within a cab. Rather, there aremany different enclosures and environments to which the followingdisclosure is applicable, such as air intake into an engine orenvironmental enclosure. As one non-limiting example, the followingdisclosure will discuss the disclosed embodiments as applied to avehicle cab.

The exemplary embodiments disclosed herein can be used with the airprecleaner and method associated with the Sy-Klone RESPA® Cab AirQuality System. Additionally, features of the embodiments can beunderstood with reference to the air precleaners and methods disclosedin commonly owned U.S. patent application Ser. No. 11/877,036 filed Oct.23, 2007 (now U.S. Pat. No. 8,007,565 issued Aug. 30, 2011) and U.S.patent application Ser. No. 14/536,849 filed Nov. 10, 2014, the entiredisclosures of which are incorporated herein by reference.

One solution to the problems discussed above is repeated or continuousmonitoring of pertinent environmental data, repeated or continuousreporting of the data, and the ability for the system and its sensors tomodify the cab environment while driving cab activity controlled by thesystem.

The monitoring may produce data and output the data to the owner ormanager of a health and safety program so that corrective action can betaken to protect the cab operator from exposure. Essentially, the caboperator or owner instructs the disclosed system how the cab is toperform, and the system uses its sensors to collect the data, analyzethe data, and effect the desired outcome, which in the embodiments canbe done continuously and instantaneously.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary air precleaner.

FIG. 2 is a diagrammatic view showing airflow through the precleaner.

FIG. 3 is a first axial side perspective view of a portion of theprecleaner housing.

FIG. 4 is a second axial side perspective view of the portion of theprecleaner housing.

FIG. 5 is a second axial side perspective view of the portion of theprecleaner housing with a modified outlet.

FIG. 6 is a diagram showing various functions and connections of a RESPAcontrol module.

FIG. 7 is a perspective view of the RESPA control module.

FIG. 8 is a side view of the RESPA control module.

FIG. 9 is a top view of the RESPA control module.

FIG. 10 is a perspective view of an inside of a module top.

FIG. 11 is a side view of the module top.

FIG. 12 is a perspective top view of the module top.

FIG. 13 is a perspective top view of a module base.

FIG. 14 is a top view showing the inside of the RESPA control modulewith a circuit board.

FIG. 15 is a bottom perspective view of the RESPA control module.

FIG. 16 is a front view of the circuit board.

FIG. 17 is a rear view of the circuit board.

FIG. 18 is a rear view of an RCM antenna board.

FIG. 19 is a front view of the RCM antenna board.

FIG. 20 is a perspective view of an antenna riser.

FIG. 21 is a perspective view of an antenna spacer.

FIG. 22 is a first axial side view showing the inside of the portion ofthe precleaner housing with the RESPA control module and the RCM antennaboard mounted.

FIG. 23 is a second axial side view showing the inside of the portion ofthe precleaner housing with the RESPA control module mounted.

FIG. 24 is a diagram showing various functions and connections of afilter ID ring.

FIG. 25 is a top view showing a first embodiment of the filter ID ring.

FIG. 26 is a top view showing a modified embodiment with the filter IDring in a molded ring body.

FIG. 27 is a top view showing the molded ring body without the filter IDring.

FIG. 28 is a perspective view showing a filter with the molded ring bodyand filter ID ring mounted thereto.

FIG. 29 is a perspective view showing another modified embodiment withthe filter ID ring in a ring housing.

FIG. 30 is a perspective view showing the filter ID ring in the ringhousing rotated from the position shown in FIG. 29 .

FIG. 31 is a diagram showing various functions and connections of anadvisor module.

FIG. 32 is a top perspective view showing an advisor housing.

FIGS. 33A and 33B are additional views showing the advisor housing.

FIG. 34 is a bottom perspective view showing the advisor housing.

FIG. 35 is a top view showing the advisor housing.

FIGS. 36A to 36C are views showing the advisor module with the advisorhousing assembled.

FIG. 37 is a view of the components forming the advisor module includinga front view of the printed circuit board of the advisor module.

FIG. 38 is a rear view of the printed circuit board of the advisormodule.

FIGS. 39A to 39C are views showing an ambient pressure sensor (APS).

FIGS. 40A and 40B are perspective views of an APS housing.

FIGS. 41A to 41C are additional views of the APS housing.

FIG. 42 is a front view of a printed circuit board used with the ambientpressure sensor and other devices.

FIG. 43 is a rear view of the printed circuit board.

FIG. 44 is a view of the components forming the ambient pressure sensor.

FIG. 45 is a view of the components forming the ambient pressure sensorin an assembled stated.

FIG. 46 is a view of an APS gasket.

FIG. 47 is a view of a tube hole formed in the portion of the precleanerhousing.

FIG. 48 is a view of an ambient pressure ventilation tube installed inthe tube hole.

FIG. 49 is a view of a pressure ventilation tube rain cap installed overthe ambient pressure ventilation tube.

FIG. 50 is a perspective view of the ambient pressure ventilation tube.

FIG. 51 is a perspective view of the pressure ventilation tube rain cap.

FIG. 52 a perspective view of one embodiment of an airflow controlvalve.

FIG. 53 is a perspective view of an operating condition lamp.

FIG. 54 is a perspective view of a dust monitor with the printed circuitboard of FIG. 42 .

FIG. 55 is a perspective view of a cab using the cab air quality system.

FIG. 56 is a top perspective view showing a modified embodiment of theairflow control valve with a valve disk in a first position.

FIG. 57 is a top perspective view showing the modified embodiment of theairflow control valve with the valve disk in a second position.

FIG. 58 is a side perspective view showing the modified embodiment ofthe airflow control valve.

FIG. 59 is a side perspective view showing the modified embodiment ofthe airflow control valve rotated from the view in FIG. 58 .

FIG. 60 is a rear view of another modified embodiment of the airflowcontrol valve.

FIG. 61 is a side perspective view of the other modified embodiment ofthe airflow control valve.

FIG. 62 is a front view of the other modified embodiment of the airflowcontrol valve.

FIG. 63 is a top view of a motor control module.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Exemplary embodiments of an air quality monitoring and control systemare described below in detail.

The air quality monitoring and control system according to oneembodiment includes an air precleaner 1, a RESPA control module 100, afilter identification ring 200 (hereinafter, “filter ID ring”), anadvisor module 300, a plurality of sensors, and other associated deviceswhich will be discussed below. The RESPA control module 100, the filterID ring 200, the advisor module 300, and the sensors communicate witheach other to effect the repeated monitoring of all pertinentenvironmental data, reporting of the data, and modification of the cabenvironment when required. The repeated monitoring and reporting can becontinuous or intermittent.

It should be understood that the air precleaner 1 is a device that hasprecleaning, filtering, and pressurizing capabilities, as describedbelow. In other words, the term “precleaner” does not refer to a devicethat merely performs precleaning. The precleaner 1 is configured topreclean, filter and pressurize in the manner described below. The airprecleaner 1 is a smart, electronically controlled intake systemdesigned to monitor and/or control one or more of airflow, air quality,air temperature, pressure drop on an air filter 7, temperaturedifferential between outside and inside the air precleaner 1, filterlife, and other parameters.

The filtration medium (air filter medium) may be selected based on theenvironment in which it is used. For example, the filtration used in theair precleaner 1 may be self-cleaning synthetic fiber nanotechnologyoverlay, achieving 0.3 micron filtration.

The air filter 7 may be a smart filter containing a microchip 204 thatis powered by the RESPA control module 100 and that contains dataregarding the filter 7 and the history of filter use.

(1) Description of Air Precleaner

The air precleaner 1 of one embodiment is similar in some aspects to theair precleaner of U.S. patent application Ser. No. 14/536,849incorporated by reference above, yet with important structuraldifferences, some of which are discussed below. As mentioned above, theair precleaner 1 is a device that has precleaning, filtering, andpressurizing capabilities. FIGS. 1 to 5 show exemplary embodiments ofthe air precleaner 1.

As shown in FIGS. 1 and 2 , the air precleaner 1 of the disclosedembodiments comprises a flow path (shown by arrows in FIG. 2 ) extendingthrough the system from an inlet 2 to an outlet 3 of a precleanerhousing 11 having a longitudinal axis A-A. A motor-driven fan 4 islocated along the flow path to draw particulate debris-laden air intothe inlet 2 and rotate it about the longitudinal axis A-A of the systemto form a rotating flow that stratifies the debris-laden air with theheaviest particles in the outermost orbits of the rotating flow.

One or more ejector ports 5 are provided in a separator chamber endsection 32 of the precleaner housing 11 for ejecting particulatedebris-laden air from the outermost orbits of the stratified rotatingflow in the separator chamber 31 of the air precleaner 1. The volume ofthe debris-laden air may be compressed by an airflow managementstructure (12, 13, 29) within the air precleaner 1 as it moves throughstationary vanes 13 to increase the air velocity and is rotated by theairflow management structure.

The airborne debris remains in the outermost orbits of the rotating airwithin the separator chamber 31 of the air precleaner 1 until it reachesthe ejector port(s) 5 at the lower end of the separator chamber 31 whereit is ejected back into the environment. The airflow that has beenstripped of most of the debris, in the innermost orbits of thestratified rotating flow within the separator chamber 31, is drawnthrough the filter 7 by the pressure differential between the precleanerhousing 11 and the outlet 3 (B″) and flows out through the filter 7 andinto an air filter internal passage 8. The filtered air then flows tothe clean air outlet 3 of the air precleaner 1 and to a downstreamdevice, such as an internal combustion engine or cab ventilation system,connected to the outlet 3.

Debris-laden air is reliably ejected because positive pressure ismaintained inside the separator chamber 31 during operation. This is dueto the fact that the amount of air pulled by the fan 4 into the airprecleaner 1 through the inlet 2 is greater than the amount of airejected through the ejector ports 5 or the clean air outlet 3. Thepressure differential results in a constant positive pressure maintainedinside the separator chamber 31. As a result, the heavy particulatematter separated in the separator chamber 31 can be ejected through theejector port(s) 5 rather than collecting on the air filter 7.

Within the precleaner housing 11, the motor-driven fan 4 has a fan blade9 mounted on a fan motor 28. The fan motor 28 can be a brushed motor ora brushless motor. Advantages of using a brushless motor include higherefficiency, lower susceptibility to mechanical wear, increased torque,and reduced noise. For the purpose of the following description, the fanmotor 28 is brushless.

The fan blades 9 may be located below the air inlet screen 6 and alongthe flow path upstream of the airflow management structure to drawparticulate debris-laden air into the inlet 2 and flow the debris-ladenair along the flow path. The airflow management structure inside theprecleaner housing 11 may include a manifold 12 (shown in FIGS. 4 and 5), the stationary vanes 13, and a shroud 29 (shown in FIG. 22 ) whichare both located inside the separator chamber 31. Specifically, themanifold 12 and the shroud 29 are disposed on opposite axial ends of theseparator chamber 31. The shroud 12 is configured to maintaincentrifugal flow of the air inside the separator chamber 31 toward thewalls of the separator chamber 31 forming the precleaner housing 11. Themanifold 12 may taper outwardly downstream of the fan blade 9, leavingan outer annular passage with circumferentially spaced, angled,stationary vanes 13 of the airflow management structure connecting themanifold 12 to the precleaner housing 11.

The stationary vanes 13 may take different forms. In one embodiment, thestationary vanes 13 are formed integrally with the precleaner housing 11and the manifold 12. In this case, the vanes 13 may be formed of amaterial similar to or the same as the material forming the precleanerhousing 11 and the manifold 12.

As seen in FIGS. 3 to 5 , the precleaner housing 11 may be configured toaccommodate the installation of the RESPA control module 100 and an RCMantenna board 118 (described in detail below). In particular, holes maybe provided in the housing 11 to accommodate a power cable 14 and apressure ventilation tube rain cap 15 (described in detail below). Thepower cable 14 provides power to the RESPA control module 100. Notches(not shown) may be provided in the shroud 29 where the power cable 14passes under the shroud 29 and connects to the RCM antenna board 118,and where power lead wires 116 and antenna wires 117 pass under theshroud 29 and connect to the RESPA control module 100. FIG. 4 is a viewof one embodiment of the housing 11 having a three-inch diameter outlet3. FIG. 5 is a view of another embodiment of the housing 11 having afour-inch diameter outlet 3. Of course, it should be understood that thediameter of the outlet 3 may vary as needed.

(2) Description of RESPA Control Module

The RESPA control module 100 (also called “RESPA® Control Module” or“RCM”) may be permanently mounted within the air precleaner 1. The RCM100 receives data from all sensors mounted in and around the precleanerhousing 11, analyzes the data, and proactively changes the operation ofthe RESPA intake system. FIG. 6 shows various functions and connectionsof the RESPA control module 100. Of course, it will be understood thatthe functions and connections of the RESPA control module 100 are notlimited to those shown in FIG. 6 . The RESPA control module 100 may beconnected to the advisor module 300 via a radio (or other suitablecommunication means) which is built into the RESPA control module 100.The RESPA control module 100 may be powered by the machine on which theair precleaner 1 is mounted, or may receive power from any othersuitable power source.

The RESPA control module 100 includes a module housing 101 formed of amodule top 102 and a module base 103. The module housing 101 may beformed by, for example, polypropylene injection molding. FIGS. 7 to 9and 15 show the module top 102 assembled to the module base 103. FIGS.10 to 12 show the module top 102 separated from the module base 103, andFIG. 13 shows the module base 103 separated from the module top 102. Asshown in FIGS. 7 to 13 , the module top 102 is sized so as to fit insidethe module base 103. The module top 102 may be provided with one or moremale posts 1021 which fit with one or more female posts 1031 formed onthe module base 103, thereby assembling the module top 102 to the modulebase 103.

As seen in FIG. 10 , an internal area of the module top 102 is dividedinto three separate compartments: a first compartment 109, a secondcompartment 110 and a third compartment 111. Each compartment is sealedin an air-tight manner so as to be fluidly separated from the othercompartments. As will be discussed in detail further below, eachcompartment houses a corresponding sensor.

As seen in FIGS. 10 and 12 , the module top 102 has a first hole 104formed off-center on a top surface of the module top 102, and a secondhole 105 formed at the center of a side surface of the module top 102.The first hole 104 communicates with the first compartment 109, and thesecond hole 105 communicates with the second compartment 110. An ambientpressure ventilation tube 17 (described in detail below) may be insertedinto the first hole 104. An outlet pressure tube (not shown) may beinserted into the second hole 105. Specifically, the outlet pressuretube has a first end inserted into the second hole 105 and a secondopposite end inserted into a hole formed in the outlet 3. Alternatively,a fastener 1051 (such as a brass screw) may be inserted into the secondhole 105 as seen in FIG. 15 when the outlet pressure tube is not used.

As shown in FIG. 13 , the module base 103 has a third hole 106, a fourthhole 107 and a fifth hole 108, all of which are formed on a side surfaceof the module base 103. The fourth hole 107 communicates with the firstcompartment 109, the third hole 106 communicates with both the secondhole 105 and the second compartment 110, and the fifth hole 108communicates with the third compartment 111. The first end of the outletpressure tube (not shown) is inserted into both the third hole 106 andthe second hold 105.

Inside the module housing 101, a circuit board 112 is disposed as shownin FIG. 14 . FIG. 16 is a view showing a front surface of the circuitboard 112, while FIG. 17 shows a rear surface of the circuit board 112.The circuit board 112 includes a microchip with a central processingunit (CPU) and a memory (e.g., RAM). The circuit board 112 is furtherprovided with plural sensors. According to this embodiment, threesensors 113, 114 and 115 are included in the module housing. Of course,the number of sensors is not limited to three. The RESPA control module100 can monitor one or more of the pressure, temperature, and humidityof ambient air using a first pressure sensor 113 disposed in the firstcompartment 109. Specifically, the first pressure sensor 113communicates with the ambient air via the first hole 104 and the ambientpressure ventilation tube 17 discussed in detail further below. TheRESPA control module 100 can further monitor one or more of thepressure, temperature, and humidity of air inside the precleaner housing11 using a second pressure sensor 115 disposed in the third compartment111. Specifically, the second pressure sensor 115 communicates with theair inside the precleaner housing 11 due to leakage of the air throughmating surfaces of the module top 102 and the module base 103. In otherwords, because the module top 102 and the module base 103 are fittedtogether without any sealant at the mating surfaces, the air inside theprecleaner housing 11 leaks to the inside of the third compartment 111,thereby reaching the second pressure sensor 115. The RESPA controlmodule 100 can additionally monitor one or more of the pressure,temperature, and humidity of air flowing through the outlet 3 of the airprecleaner 1 using a third pressure sensor 114 disposed in the secondcompartment 110. Specifically, the third pressure sensor 114communicates with the clean (filtered) air flowing through the outlet 3via the second hole 105, the third hole 106, the outlet pressure tube,and the hole formed in the outlet 3. Accordingly, the RESPA controlmodule 100 can, for example, monitor one or more of the pressure,temperature and humidity of the ambient air, the air inside theprecleaner housing 11, and the air at the outlet 3. It should beunderstood that, although certain sensors in this disclosure arereferred to as “pressure sensors,” they may be configured to detect andmeasure one or more of pressure, temperature, and humidity, as discussedabove.

The circuit board 112 of the RESPA control module 100 is provided withthe power lead wires 116 connected thereto for providing power to theRESPA control module 100 via the RCM antenna board 118 (described indetail below). In particular, the power lead wires exit through thefifth hole 108 of the module housing 101 for connection with the RCMantenna board 118. The circuit board 112 is also provided with theantenna wires 117 which exit through the fourth and fifth holes 107 and108 of the module housing 101 for connection with the RCM antenna board118. The power lead wires 116 and the antenna wires 117 may exit themodule housing 101 as separate wires, as seen in FIGS. 7 to 9 and 14 ,or may be covered by a sheath 121 as shown in FIG. 15 . As will bediscussed below, the RCM antenna board 118 may be used to provide powerto the RESPA control module 100. In addition, the circuit board 112 mayhave Bluetooth® capabilities, WiFi capabilities (e.g., 802.11 WiFi), andradio capabilities for radio transmission. The circuit board 112 mayfurther have a high voltage protection circuit, electromagneticinterference (EMI) circuitry, and inner-board shielding.

The RESPA control module 100 has an integrated accelerometer whichallows the sensors in the RESPA control module 100 (which can besensitive to movement) to function accurately in high vibrationenvironments such as a cab or an engine by measuring vibration andremoving a vibration component from the sensor measurements. Theaccelerometer is integral with the pressure sensors 113, 114 and 115.

The RESPA control module 100 communicates with and is connected to theRCM antenna board 118 disposed within the module housing and shown inFIGS. 18, 19 and 22 . The microchip of the RESPA control module 100 canbe powered through the power cable 14 and through the RCM antenna board118, thus allowing recording and sending of data by the precleanersystem without the need for any connected power source. As will bedescribed further below, the RCM antenna board 118 provides power to thefilter ID ring 200 as well by broadcasting an electrical field into theprecleaner housing 11.

As seen in FIGS. 18 and 19 , the RCM antenna board 118 may be made froma printed circuit board having solder points 119 for connecting theantenna wires 117 and the power lead wires 116 of the RESPA controlmodule 100 to the RCM antenna board 118. The power cable 14 describedabove is shown in FIGS. 18 and 19 and may be a shielded four-lead wiredesigned to reduce electromagnetic emissions. The RCM antenna board 118is additionally provided with power leads 120 and an antenna wire 24made of, for example, copper. Power is provided to the RCM controlmodule 100 from the power cable 14 through the power leads 120 andthrough the power lead wires 116. In other words, power is sent from thepower cable 14, through the power leads 120, then through the power leadwires 116 to the RCM control module 100. Once the RCM control module 100receives the power, the RCM control module 100 energizes the antennawire 24 of the RCM antenna board 118, thereby causing the RCM antenna118 to emit an electrical field as described below.

FIG. 22 is a view taken on a first axial side of the precleaner housing11 along the longitudinal axis A-A. FIG. 22 shows the RCM antenna board118 mounted in the precleaner housing 11. The RCM antenna board 118 mayhave a horseshoe shape, or substantially horseshoe shape, so as to bemounted on a surface of the manifold 12. In the mounted position seen inFIG. 22 , the solder points 119 are positioned for connecting to thepower lead wires 116 and the antenna wires 117 of the RESPA controlmodule 100.

FIG. 23 is a view taken on a second axial side of the precleaner housing11 along the longitudinal axis A-A. As seen in both FIGS. 22 and 23 ,the RESPA control module 100 is positioned inside the precleaner housing11 between two of the stationary vanes 13 adjacent the outlet 3 of theair precleaner 1. The RCM antenna board 118 and the RESPA control module100 are mounted to be positioned relative to each other, as shown inFIG. 22 , such that the power lead wires 116 and the antenna wires 117of the RESPA control module 100 may be connected to the solder points119 of the RCM antenna board 118. In this way, the RCM antenna board 118provides power (via the power lead wires 116) to, and also communicates(via the antenna wires 117) with, the RESPA control module 100.

As described above, the module housing 101 may include the module top102 and the module base 103. The upper surface of the module top 102 maybe shaped to match and fit the curve of the inner wall of the precleanerhousing 11. The lower surface of the module base 103 may be shaped tomatch and fit the curve of the outer wall of the manifold 12. Thus, theRESPA control module 100 can be held within the precleaner housing 11between two of the stationary vanes 13 by the stationary vanes 13, theouter wall of the manifold 12, and the inner wall of the precleanerhousing 11. Of course, this is only one example of the shape the modulehousing 101 may take, and clearly the module housing 101 could have adifferent shape for mounting in a different orientation and positionwithout inhibiting the functioning of the system.

Additionally, one or more antenna risers 122 may be provided between theRCM antenna board 118 and the manifold 12. The antenna riser 122 may bemade of various materials, including but not limited to polylactic acid(PLA) rapid prototype plastic and injection-molded polypropylene. Theantenna riser 122 acts as a spacer between the RCM antenna board 118 andthe manifold 12. In addition, one or more antenna spacers 123 may beprovided between the RCM antenna board 118 and the shroud 29. Theantenna spacer 123 may be made of various materials, including but notlimited to polylactic acid (PLA) rapid prototype plastic andinjection-molded polypropylene. The antenna spacer 123 acts as a spacerbetween the RCM antenna board 118 and the shroud 29 and presses down onthe RCM antenna board 118 to hold the RCM antenna board 118 in place.Thus, the antenna riser 122 and the antenna spacer 123 are positioned onopposite axial sides of the RCM antenna board 118.

As described above, the first, second and third pressure sensors 113,115, 114 are positioned inside each respective compartment of the modulehousing 101 so as to accurately detect the pressure and other parametersof the airflow to which the sensors 113, 115 and 114 are designated, asshown in FIGS. 14 and 16 . Specifically, the first pressure sensor 113is positioned in the first compartment 109 to receive and monitor thepressure and other parameters of the ambient airflow. The secondpressure sensor 115 is positioned in the third compartment 111 toreceive and monitor the pressure and other parameters of the airflowinside the precleaner housing 11. The third pressure sensor 114 ispositioned in the second compartment 110 to receive and monitor thepressure and other parameters of the airflow at the outlet 3 of the airprecleaner 1.

These three pressure sensors 113, 115 and 114 provide real-time dataregarding the temperature differential and pressure differential betweenthe inlet 2 and the outlet 3 of the precleaner housing 11. This dataallows for improvements in various areas such as power, fuel economy,and HVAC efficiency. Moreover, the pressure sensors 113, 115 and 114allow for the airflow and other parameters to be continuously measuredand output as data from the RESPA control module 100 to variousconnected devices, including the advisor module 300 (described below).

As described above, the first pressure sensor 113 disposed in the firstcompartment 109 communicates with the ambient air via the first hole104. To facilitate this communication, the ambient pressure ventilationtube 17 (shown in FIG. 50 ) is inserted through the precleaner housing11 via a tube hole 18 seen in FIGS. 47 and 48 . A first end of theambient pressure ventilation tube 17 protrudes from the precleanerhousing 11, as seen in FIG. 48 . A second opposite end of the ambientpressure ventilation tube 17 fits into the first hole 104. The pressureventilation tube rain cap 15, shown in FIG. 51 , is provided to coverthe ambient pressure ventilation tube 17, as seen in FIG. 49 . Thepressure ventilation tube rain cap 15 has two attachment holes 20 forsecuring the pressure ventilation tube rain cap 15 to the precleanerhousing 11 with, for example, fasteners. The pressure ventilation tuberain cap 15 is further provided with a raised section 21 arranged torest atop the ambient pressure ventilation tube 17 without disruptingthe pressure readings of the first pressure sensor 113. The raisedsection 21 allows water to flow under the raised section 21 and over theambient pressure ventilation tube 17 without clogging the ambientpressure ventilation tube 17. In addition, as seen in FIG. 50 , theambient pressure ventilation tube 17 has one or more tube protrusions 19formed at the first end of the ambient pressure ventilation tube 17 thatprotrudes from the precleaner housing 11. The tube protrusions 19contact the raised section 21 of the pressure ventilation tube rain cap15 so as to prevent the pressure ventilation tube rain cap 15 fromsealing the ambient pressure ventilation tube 17, thereby avoiding thesituation in which sealing of the ambient pressure ventilation tube 17would result in the pressure failing to equalize between the ambient airand the air inside the precleaner housing 11.

In addition, the RESPA control module 100 may be configured to set up alocal area network (LAN) to communicate with the motor and/or the airfilter 7 of the air precleaner 1. An IP address may be assigned to theRESPA control module 100 so that the RESPA control module 100 can beaccessed through a local wide area network (WAN).

Furthermore, the RESPA control module 100 may be accessed by a userterminal, such as a cellular phone application, to read the dataobtained by the RESPA control module 100.

The RESPA control module 100 serves various functions, includingproviding power to the filter ID ring 200, logging data into the filterID ring 200, reading data stored on the filter ID ring 200, sensingpressure and other airflow parameters, and relaying all of this data tothe advisor module 300. The RESPA control module 100 regulates andcontrols all parameters of the air filter 7 and intake system, andcommunicates with the advisor module 300 to provide data and receiveinstructions. These functions will be described in greater detail below.

The air quality monitoring and control system may further include amotor control module 40 as shown in FIG. 63 . The motor control module40 includes a circuit board 41 housed in a casing 42. The circuit board41 includes resistors, diodes, capacitors, and regulators which relayvoltage data to the RESPA control module 100 and prevent over-voltage inthe motor 28. The casing 42 may be a heat sink. Three power leads areconnected to the circuit board 41. Specifically, a power lead 43connects the circuit board 41 to the cab operated by the operator, apower lead 44 connects the circuit board 41 to the motor 28, and a powerlead 45 connects the circuit board 41 to the RESPA control module 100.The motor control module 40 has various advantageous capabilities,including EMI and EMF suppression via filters provided on the circuitboard 41, motor over-voltage protection, motor speed control, motorvoltage regulation, and data transfer to the RESPA control module 100for data logging and external communication to the advisor module 300.The motor control module 40 may send and receive data to and from theRESPA control module 100, and to and from the fan motor 28. The motorcontrol module 40 may determine the temperature of the fan motor 28 ofthe air precleaner 1 by monitoring motor voltage. When the motor voltageis excessively high or low, or when an unsuitable filter is being used,the motor control module 40 may be configured to turn off the motor 28.Also, the motor control module 40 may turn off the motor 28 or adjustthe speed of the motor 28 in response to instructions from the RESPAcontrol module 100. The motor control module 40 may automaticallycontrol the motor 28 or may control the motor 28 based on commandsreceived from the RESPA control module 100.

The motor control module 40 may vary the motor speed based upon theneeds of the cabin or engine to increase pressure or overcome a pressuredrop on the filter 7.

The motor control module 40 may connect to the motor 28 directly to readand record the voltage running through the motor 28. The motor controlmodule 40 may be programmed to turn the fan motor 28 off when there isover- or under-voltage, or when the motor 28 reaches a highertemperature, such as 70° C. The motor control module 40 may then turnthe motor 28 on again when the motor 28 drops to a lower temperature,such as 50° C.

When programmed operating parameters are violated, the RESPA controlmodule 100 may cause an alarm message to be sent to the advisor module300. Alternatively or additionally, the data that is continuouslystreaming from the RESPA control module 100 and other sensors to theadvisor module 300 may be analyzed by the advisor module 300, inresponse to which the advisor module 300 may make the determination tosound an alarm.

Alarm modes include but are not limited to visual, audible and/or hapticalarms from the advisor module 300 to the operator, a signal light onthe top of the cab, and a text message or email sent to an appropriateperson or system to notify of the alarm condition. As one example of thesignal light, FIG. 53 shows an operating condition lamp 16. Theoperating condition lamp 16 may be an automatic three-color LED lampcontrolled by the advisor module 300 using a suitable communicationmeans such as WiFi. For example, the operating condition lamp 16 cannotify the operator of an alarm condition using red light, a warningcondition using yellow light, and a safe condition using green light.

The RESPA control module 100 is configured to communicate with multiplesensors in the system. Specifically, the RESPA control module 100 maycommunicate with up to 255 sensors simultaneously.

Also, the RESPA control module 100 may be programmed from the advisormodule 300 or through another control means, such as a cellular phoneapplication. The RESPA control module 100 may operate as a slave to theadvisor module 300 or independently of the advisor module 300. The RESPAcontrol module 100 may operate independently of all devices includingthe advisor module 300.

The RESPA control module 100 may be configured to automatically syncwith the advisor module 300, the filter ID ring 200, the brushless motor28, and/or a cellular phone application.

The RESPA control module 100 is configured to communicate continuouslywith the advisor module 300 to provide data such as the type of filter 7being used, the pressure drop on the filter 7 (determining when thefilter 7 needs to be changed), and the airflow into the cabin using theoutlet diameter, outlet pressure, and the “K” Factor to continuouslycalculate outlet airflow.

(3) Description of Filter ID Ring

The filter ID ring 200 (also called “filter identification component”)is an inert filter ring having a specific shape to fit to the outercircumference of the air filter 7. The circular configuration allows thefilter 7 to be mounted within the precleaner housing 11 in anyorientation and still achieve the same level of functionality. Thefilter ID ring 200 is configured to communicate with the RESPA controlmodule 100. FIG. 24 shows various functions and connections of thefilter ID ring 200. Of course, it will be understood that the functionsand connections of the filter ID ring 200 are not limited to those shownin FIG. 24 . The filter ID ring 200 is not limited to the shape of aring and may be provided in other shapes and configurations. Forexample, in an alternative embodiment, the filter ID ring 200 may beprovided as a computer chip directly mounted into the filter 7. In yetanother alternative embodiment, the filter ID ring 200 may be integrated(embedded) in the body of the filter 7 at the point of manufacture (POM)of the filter 7. The following discussion will focus on the embodimentof the ring-shaped filter ID ring 200.

The filter ID ring 200 may be attached (e.g., glued or molded) to theair filter 7 such that, when the air filter 7 is mounted inside theprecleaner housing 11, the filter ID ring 200 is sufficiently close tothe RESPA control module 100 to receive the appropriate frequency forthe RCM antenna board 118 to provide the filter ID ring 200 with powerto operate and communicate. In other words, the filter ID ring 200 maybe powered by an electrical field broadcast by the RCM antenna board 118into precleaner housing 11. Communication may also occur via thiselectrical field. In the absence of the RESPA control module 100 and theRCM antenna board 118, the filter ID ring 200 is inert.

One exemplary embodiment of the filter ID ring 200 is shown in FIG. 25 .The filter ID ring 200 is formed of an antenna wire 201 and a printedcircuit board 202 having two solder pads 203. The antenna wire 201 maybe, for example, a copper wire enclosed by an antenna wire cover 205made of, for example, polypropylene. A first end of the antenna wire 201is connected to the printed circuit board 202 at one of the solder pads203, while a second end of the antenna wire 201 is connected to theprinted circuit board 202 at the other of the solder pads 203. Theprinted circuit board 202 may additionally include an RFID chip 204 andone or more resistors and capacitors. The RFID chip 204 has a memorywhich stores information about the air filter 7 to which the filter IDring 200 is attached. The memory may include discrete memory and/or RAMmemory, with the amount of memory being customizable. The filter ID ring200 stores manufacturing information such as the serial number,manufacture date, usage, and part number of the air filter 7. The filterID ring 200 may be programmed wirelessly with filter data at the pointof manufacture.

The filter ID ring 200 may be directly attached to the air filter 7 suchthat the filter ID ring 200 wraps around the circumference of the airfilter 7. Alternatively, as shown in FIGS. 26 and 27 , the filter IDring 200 may be encased in a molded ring body 206. The filter ID ring200 may be wrapped in one or more loops within the molded ring body 206,depending on the required frequency and power. In other words, differentnumbers of loops will provide different frequencies and power. FIG. 26shows a front surface of the molded ring body 206 on which the filter IDring 200 is mounted, and FIG. 27 shows the front surface of the moldedring body 206 without the filter ID ring 200 mounted thereto. The moldedring body 206 may be formed by, for example, plastic polypropyleneinjection. The molded ring body 206 is provided with one or more grooves207 which tightly grip the antenna wire cover 205 and the printedcircuit board 202. The molded ring body 206 having the filter ID ring200 mounted therein is configured to be directly attached to the airfilter 7 such that the molded ring body 206 wraps around thecircumference of the air filter 7, as shown in FIG. 28 . A rear surfaceand a side surface of the molded ring body 206 are seen in FIG. 28 ,such that the antenna wire 201 is facing downward in FIG. 28 .Alternatively, the molded ring body 206 may be flipped such that theantenna wire 201 is facing upward in FIG. 28 , with an additional covermember (not shown) covering the front surface of the molded ring body206.

As an alternative to the molded ring body 206, the filter ID ring 200may be housed in a ring housing 208 as shown in FIGS. 29 and 30 . Thering housing 208 may be, for example, prototype polylactic acid plasticor polypropylene injection molded. The ring housing 208 is shaped to fitinto the throat of the filter cap of the air filter 7. As seen in FIGS.29 and 30 , the filter ID ring 200 is wrapped around the ring housing208 and is secured by a plurality of restraining posts 209. The filterID ring 200 may be wrapped in one or more loops around the ring housing208, depending on the required frequency and power. In the example shownin FIGS. 29 and 30 , the ring housing 208 has three restraining posts209, but the number of restraining posts 209 may be more or less thanthree. The restraining posts 209 are arranged and configured to restrainthe filter ID ring 200 such that wire tension of the antenna wire 201 ismaintained.

The filter ID ring 200 may be mounted within the precleaner housing inany orientation as long as the filter ID ring 200 is mounted at alocation sufficiently proximate to the RESPA control module 100 suchthat the RCM antenna board 118 and the antenna wire 201 are continuouslycommunicating with each other through the electrical field broadcast bythe RCM antenna board 118. The specific orientation of the filter IDring 200 relative to the RESPA control module 100 within the precleanerhousing 11 ensures efficient communication between the filter ID ring200 and the RESPA control module 100. The antenna wire 201 is tuned tothe frequency of the antenna wire 124 of the RCM antenna board 118 toallow for communication between the RESPA control module 100 and thefilter ID ring 200 inside the precleaner housing 11. The electricalfield is broadcast by the RCM antenna board 118 into the precleanerhousing 11, and the antenna wire 201 of the filter ID ring 200 picks ofthe electrical field and directs the energy to the RFID chip 204 of thefilter ID ring 200. As a result, power can be provided from the RESPAcontrol module 100 (the RCM antenna board 118) to the filter ID ring200, data can be logged into the filter ID ring 200 from the RESPAcontrol module 100, and data stored on the filter ID ring 200 can beread by the RESPA control module 100. Energizing of the RFID chip 204 ofthe filter ID ring 200 is continuous as long as the RFID chip 204 isdisposed within the energy field created within the precleaner housing11 by the RCM antenna board 118.

Additionally, during operation the RESPA control module 100 maycontinuously read and write data from and to the filter ID ring 200.Two-way communication between the RESPA control module 100 and thefilter ID ring 200 allows for continuous data storage and retrieval. Asdiscussed above, the RESPA control module 100 may communicate with thefilter ID ring 200 using the electrical field created by the RCM antennaboard 118. The electrical field provides electrical current to thefilter ID ring 200, and also allows for the two-way communicationbetween the RESPA control module 100 and the filter ID ring 200.

The RESPA control module 100 continuously logs data to the filter IDring 200. This data may include, but is not limited to, one or more offilter pressure, ambient pressure, outlet airflow, motor voltage andtemperature, ambient temperature and humidity, precleaner housingtemperature and humidity, and precleaner housing outlet temperature andhumidity.

The filter ID ring 200 may permanently record and continuously updatethe usage of the air filter 7 and notify the advisor module 300 when theair filter 7 has reached the end of its life (e.g., the air filter 7 hasbeen used for a predetermined number of hours, or the air filter 7 hasbecome too restrictive). The filter ID ring 200 effectively results in aself-aware filter 7 that self-records and permanently stores allsignificant events and data points during the life of the filter 7. As aresult, there is no need for physically inspecting the filter 7 todetermine the real-time status of the filter 7.

The filter ID ring 200 may also be accessed by a user terminal, such asa cellular phone application, to read the data stored in the filter IDring 200.

(4) Description of Advisor Module

The advisor module 300 (also called “RESPA® Advisor”) may be a wirelessdevice that uses a radio signal to communicate with the RESPA controlmodule 100, which in turn is communicating with the filter ID ring 200.The advisor module 300 may have both radio and cellular communicationcapabilities. The advisor module 300 may also piggy-back on local WiFinetworks without logging into the networks. FIG. 31 shows variousfunctions and connections of the advisor module 300. Of course, it willbe understood that the functions and connections of the advisor module300 are not limited to those shown in FIG. 31 .

FIGS. 32 to 38 provide various views of the components of the advisormodule 300. As seen in FIG. 32 , the advisor module 300 is provided withan advisor housing 301. The advisor housing 301 may be formed of, forexample, injection-molded acrylonitrile butadiene styrene (ABS) plastic.The advisor housing 301 includes an advisor top 302 and an advisor base303. The advisor top 302 and the advisor base 303 are assembled by asnap-together configuration. The snap-together configuration is formedby two snap holes 321 formed in the advisor base 303 and two snap posts322 formed in the advisor top 302.

The advisor top 302 includes a display screen mounting portion 304, arecessed portion 305, one or more air vents 306, and a power cable hole307. The display screen mounting portion 304 is configured to hold adisplay screen 308 which may be, for example, a touch screen by which auser may operate the advisor module 300. FIG. 37 shows an example of thedisplay screen 308. The display screen mounting portion 304 further hasa chamfered area 311 to allow access to the outer areas of the displayscreen 308. As seen in FIG. 34 , the advisor top 302 has displaymounting posts 309 formed on an inner surface of the advisor top 302.Although only the one display mounting post 309 is seen in FIG. 34 , theadvisor top 302 has four display mounting posts 309 arranged around thedisplay screen mounting portion 304, the four display mounting posts 309corresponding to four display screen holes 310 shown in FIG. 37 .

The recessed portion 305 is recessed from the upper-most outer peripheryof the advisor top 302 so as to provide an area for mounting, forexample, a sticker or other indicia. The one or more air vents 306 maybe provided on one or more sides of the advisor top 302. The air vents306 ensure proper functioning of a multi-gas sensor 323 (discussedbelow). The power cable hole 307, shown in FIGS. 34 and 36C, allows apower cable 312 to pass therethrough to provide power to the advisormodule 300. The power cable 312 extends from the advisor module as seenin FIGS. 36A and 36B. The power cable 312 may be a shielded four-leadwire designed to reduce electromagnetic emissions.

As shown in FIG. 32 , the advisor base 303 includes a plurality ofmounting bosses 313 for mounting a printed circuit board 314 (shown inFIGS. 37 and 38 ). In the embodiment shown in FIG. 32 , the plurality ofmounting bosses 313 includes eight mounting bosses 313. The mountingbosses 313 correspond to circuit board holes 315 shown in FIGS. 37 and38 . The mounting bosses 313 and the circuit board holes 315 areconfigured to receive fasteners (e.g., screws) for securely mounting theprinted circuit board 314 to the advisor base 303. The mounting bosses313 are provided with a predetermined thickness to reduce the transferof vibration to the printed circuit board 314. The advisor base 303additionally is provided with a plurality of base mounting holes 316.The base mounting holes 316 mate with top mounting holes 317 formed inthe advisor top 302, and fasteners (e.g., screws) are inserted throughthe base mounting holes 316 and the top mounting holes 317 to allowmounting of the advisor module 300 to a surface (e.g., a wall). The basemounting holes 316 are formed by enlarged rings 318 and strengtheningribs 319 for compression during assembly.

FIG. 37 shows a front view of the printed circuit board 314, while FIG.38 shows a rear view thereof. The printed circuit board 314 is providedwith a plurality of sensors including, but not limited to, the multi-gassensor 323 and a pressure sensor 324. The printed circuit board 314includes a microchip with a CPU and a memory (e.g., RAM). In addition,the printed circuit board 314 may have Bluetooth® capabilities, WiFicapabilities (e.g., 802.11 WiFi), and radio capabilities for radiotransmission. The printed circuit board 314 may further have a highvoltage protection circuit, electromagnetic interference (EMI)circuitry, and inner-board shielding. As discussed above, the powercable 312 is connected to the printed circuit board 314 to provide powerthereto (e.g., 3.3 volt power supply or 5 volt power supply). Theprinted circuit board 314 may also have a haptic notification device,such as a beeper, to notify of, for example, warning situations.

Moreover, the advisor module 300 may function as a local area networkrouter. Thus, the advisor module 300 can facilitate a local network forthe sensors and communicate through proprietary radio communicationprotocol invisible to local WiFi networks.

The advisor module 300 may automatically sync with any wireless sensorlocated within radio range of the advisor module 300. For example, theadvisor module 300 can sync with the sensors (including those of theRESPA control module 100) of multiple air precleaners 1. Specifically,the advisor module 300 can communicate with up to 255 sensorssimultaneously. The advisor module 300 can also monitor cab filterperformance and engine filter performance simultaneously.

The sensors which are read and controlled by the advisor module 300 mayinclude sensors (such as the first pressure sensor 113, the secondpressure sensor 115, and the third pressure sensor 114) detecting one ormore of temperature, pressure, and humidity of the air inside theprecleaner housing 11, the air at the outlet 3, or the ambient air;sensors detecting outlet airflow cubic feet per minute (CFM); sensorsdetecting fan motor temperature and voltage; sensors detecting gas typeand gas concentration, and sensors detecting mass particleconcentration.

The advisor module 300 may be configured to automatically organize thedata received from multiple sensors. For instance, if multiple ambientpressure sensors are within range, the advisor module 300 mayautomatically average the ambient pressure readings to give a moreaccurate reading.

The display screen 308 may display data such as filter type, filterhours used, pressure differential, CO₂ concentration, and otherparameters in real time. The advisor module 300 may also report thisdata to the Internet via radio, SMS text, WiFi, general packet radioservice (GPRS), or other suitable communication means.

As described above, the display screen 308 may optionally include ahuman machine interface (HMI), such as a touch screen. However, the HMIis not essential.

As described above, the advisor module 300 may also have multiplesensors disposed on the printed circuit board 314 in the advisor housing301. In addition to the multi-gas sensor 323 and the pressure sensor324, these sensors may include an integrated accelerometer allowing foraccurate pressure readings in high vibratory environments, and atemperature and humidity sensor. The advisor module 300 may furtherinclude a real-time clock.

The advisor module 300 may be accessed and reprogrammed remotely fordata downloads or firmware updates using a communication means such asGPRS. The advisor module 300 may receive sensor updates via, forexample, text messages.

As discussed above, the advisor module 300 may be configured toautomatically sync with nearby sensors. Predetermined algorithms mayprioritize the data received from the sensors in order to produce thesafest possible cab environment. Specifically, the advisor module 300may use the sensors to monitor within the cab CO₂ and other poisonousgas concentrations, respirable dust concentrations, fresh air intake,and cab air leakage. As will be discussed further below, the advisormodule 300 may be configured to stop all air from entering the cab andfill the cab with clean air free of poisonous gas.

The air quality monitoring and control system may further include one ormore additional ambient pressure sensors (also referred to as “APS”)400, in addition to those provided in the advisor module 300. FIGS. 39Ato 45 show one exemplary embodiment of an ambient pressure sensor 400.The ambient pressure sensor 400 may be mounted on the outside of thecab. The ambient pressure sensor 400 may wirelessly connect to andcommunicate with the advisor module 300 to provide data on the ambientpressure. As discussed above, the advisor module 300 may automaticallyaverage a plurality of ambient pressure readings from distinct sensorsto give a more accurate reading. With the provision of the ambientpressure sensor 400 on the outside of the cab, the advisor module 300can subtract the internal cab pressure from the ambient pressure todetermine the pressure difference. The advisor module 300 can thendisplay the pressure difference on the display screen 308 and/ortransmit information on the pressure difference to an external device,the Internet, and so on. With the provision of the ambient pressuresensor 400, the advisor module 300 can determine the pressure differencewithout the need for ambient pressure readings of the RESPA controlmodule 100. In other words, in one embodiment the advisor module 300 andthe ambient pressure sensor 400 function together without the provisionof the RESPA control module 100.

As seen in FIGS. 39A to 45 , the ambient pressure sensor 400 includes anAPS housing 401. The APS housing 401 is formed of an APS top 402 and anAPS base 403. The APS top 402 and the APS base 403 are assembled in asnap-together arrangement. The APS top 402 and the APS base 403 may beformed of, for example, a nylon material. The APS top 402 has outerflanges 4021 with top mounting holes 404 for mating with base mountingholes 405 formed in outer flanges 4031 of the APS base 403. The topmounting holes 404 may be provided with inserts 406 (e.g., brassinserts) which function as compression limiters when the APS top 402 andthe APS base 403 are assembled further using fasteners (e.g., screws)inserted through the top mounting holes 404 and the base mounting holes405. As shown in FIG. 40A, the APS top 402 is provided with chamferedcorners 407 and strengthening ridges 408 for improved stability. The APSbase 403 has a central portion disposed between the outer flanges 4031,with the central portion being a recessed surface 409 that projects fromthe outer flanges 4031 toward and into the APS top 402. The recessedsurface 409 allows for rapid pressure change within the APS housing 401.

The ambient pressure sensor 400 further includes a printed circuit board410, as seen in FIGS. 42 to 44 . The printed circuit board 410 includesa pressure sensor configured to sense ambient pressure. The printedcircuit board 410 further includes a microchip with a CPU and a memory(e.g., RAM). In addition, the printed circuit board 410 may haveBluetooth® capabilities, WiFi capabilities (e.g., 802.11 WiFi), andradio capabilities for radio transmission. The printed circuit board 410may further have a high voltage protection circuit, electromagneticinterference (EMI) circuitry, and inner-board shielding. A power cable411 is connected to the printed circuit board 410 to provide powerthereto (e.g., 3.3 volt power supply or 5 volt power supply). As shownin FIGS. 44 and 45 , the power cable 411 is connected to the printedcircuit board 410 via a cable connector 412 installed in a power cablehole 413 formed in the APS top 402. The power cable 411 may also beprovided with a ferrite 414 configured to reduce EMI emissions from thepower cable 411.

As seen in FIGS. 44 and 46 , the ambient pressure sensor 400 is furtherprovided with an APS gasket 415. The APS gasket 415 is a member made of,for example, nylon and is inserted into the APS housing 401. The APSgasket 415 is provided to securely hold the printed circuit board 410and reduce the transfer of vibration to the printed circuit board 410.As seen in FIG. 46 , the APS gasket 415 includes a ledge 416, a strap417, and a cutout 418. The printed circuit board 410 is placed on theledge 416 and is held tightly by the ledge 416 and the inner walls ofthe APS gasket 415. The strap 417 extends above the printed circuitboard 410 to ensure that the printed circuit board 410 does not moveupward off of the ledge 416. The cutout 418 is provided to allow for thepower cable 411 to pass through the APS gasket 415 for connection withthe printed circuit board 410.

The printed circuit board 410 serves as a universal communication modulewhich may be used in a variety of locations outside of the ambientpressure sensor 400 and is not limited to use in association with theambient pressure sensor 400. In other words, the printed circuit board410 may be used with devices even in the absence of the ambient pressuresensor 400. For example, in the embodiment discussed above in which theRESPA control module 100 provides ambient pressure readings to theadvisor module 300, there may be no need for the separate ambientpressure sensor 400 on the outside of the cab. In that case, there maybe one or a plurality of printed circuit boards 410 used inside the cabto control communication between various devices and the advisor module300. One such arrangement will be discussed further below with respectto a dust monitor 600.

The air quality monitoring and control system may further include one ormore airflow control valves 500. For example, a first airflow controlvalve 500 may control airflow entering the cab, and a second airflowcontrol valve 500 may control airflow exiting the cab, therebyfunctioning as a pressure release valve for the cab. FIG. 52 shows oneexemplary embodiment of the airflow control valve 500. The airflowcontrol valve 500 may be made of, for example, polylactic acid plasticor injection-molded polypropylene. The airflow control valve 500 mayinclude a servo motor 501 to control the positions of louvers 502provided to the airflow control valve 500. The louvers 502 are disposedin a valve housing 503 having first and second axial openings 504. Theairflow control valve 500 may be WiFi-enabled and controlled directly bythe advisor module 300. Specifically, a unique algorithm may be used bythe advisor module 300 to monitor all cab parameters and adjust the flowof fresh air via the precleaner 1 and the first airflow control valve500, and adjust cab leakage via the second airflow control valve 500, tomaintain optimal operator protection. For example, the RESPA controlmodule 100 measures the airflow exiting the outlet 3 and reports theairflow measurement to the advisor module 300. Then, the advisor module300 adjusts the airflow control valves 500 by adjusting the positions ofthe louvers 502, to maintain a predetermined fresh air intake airflow.The airflow control valves 500 are controlled in this way by the advisormodule 300 to allow more fresh air to enter the cab, thereby creatingsufficient and consistent internal cab pressure while diluting harmfulgas (e.g., CO₂) concentrations. In this way, the air quality monitoringand control system continuously monitors and controls the cab pressure,fresh air intake, gas (e.g., CO₂) levels, and cab leakage to produce thesafest air quality and highest HVAC operating efficiency.

Each filter 7 will have a specific airflow limit. For example, a carbonfilter has an airflow limit of 50 cfm, while a MERV16 filter has anairflow limit of 130 cfm. The RESPA control module 100 may read thefilter ID ring 200 to determine the airflow limit associated with theparticular filter 7 being used. The RESPA control module 100 may thenprovide this information to the advisor module 300, based on which theadvisor module 300 may adjust the variables in the algorithm used tocontrol the airflow amount by controlling the first airflow controlvalve 500.

A first modified airflow control valve 500′ is shown in FIGS. 56 to 59 .The first modified airflow control valve 500′ may be made of, forexample, polylactic acid plastic or injection-molded polypropylene. Thefirst modified airflow control valve 500′ may include a servo motor 501′to control the position of a valve disk 502′ provided to the firstmodified airflow control valve 500′. The valve disk 502′ is disposed ina valve housing 503′ having first and second axial openings 504′. Thevalve disk 502′ is attached to a dowel 505′. The dowel 505′ may be madeof, for example, polylactic acid plastic or injection-moldedpolypropylene. The dowel 505′ extends across the diameter of the valvehousing 503′. A first end of the dowel 505′ is connected to a bearing506′ allowing free rotation of the dowel 505′. A second opposite end ofthe dowel 505′ is connected to the servo motor 501′ such that the servomotor 501′ may control the position of the valve disk 502′ by rotatingthe dowel 505′, thereby adjusting the airflow. The first modifiedairflow control valve 500′ may be WiFi-enabled and controlled directlyby the advisor module 300 in a manner similar to the airflow controlvalve 500 described above.

A second modified airflow control valve 500″ is shown in FIGS. 60 to 62. The second modified airflow control valve 500″ may be made of, forexample, polylactic acid plastic or injection-molded polypropylene. Thesecond modified airflow control valve 500″ may include a servo motor501″ to control the positions of two valve veins 502″ provided to thesecond modified airflow control valve 500″. The valve veins 502″ aredisposed in a valve housing 503″ having first and second valve openings504″. The valve veins 502″ are each attached to a respective dowel 505″.The dowels 505″ may be made of, for example, polylactic acid plastic orinjection-molded polypropylene. The dowels 505″ extend across the widthof the valve openings 504″. A first end of each dowel 505″ is connectedto a bearing 506″ allowing free rotation of the dowel 505″. A secondopposite end of each dowel 505″ is connected to the servo motor 501″ viaa gear assembly 507″ which is connected to the servo motor 501″ suchthat the servo motor 501″ may control the positions of the valve veins502″ by rotating the respective dowels 505″, thereby adjusting theairflow. The second modified airflow control valve 500″ may beWiFi-enabled and controlled directly by the advisor module 300 in amanner similar to the airflow control valve 500 described above.

The air quality monitoring and control system may further include thedust monitor 600 as seen in FIG. 54 . The dust monitor 600 may beinstalled in a mixing plenum 22 (described below), inside a housing (notshown) which houses both the dust monitor 600 and the printed circuitboard 410. The housing may be mounted on a vibration-reducing gasketsimilar to the APS gasket 415 to improve sensor readings from the dustmonitor 600. The dust monitor 600 is connected to the printed circuitboard 410. Specifically, as shown in FIG. 54 , the dust monitor 600 hasa plug 601 which connects to an outlet 4101 formed on the printedcircuit board 410. The printed circuit board 410 serves as a universalcommunication module and controls communication between the dust monitor600 and the advisor module 300. As a result, dust concentration readingsfrom the dust monitor are transmitted to the advisor module 300 via theprinted circuit board 410. In addition, the printed circuit board 410powers the dust monitor 600 with power provided to the printed circuitboard 410 by the power cable 411.

The dust monitor 600 monitors the dust so as to give real-timegravimetric dust measurements to the advisor module 300 via the printedcircuit board 410. Current dust monitors in the related art are notdesigned to be permanently installed in operator cabs, subject to fieldabuse and particulate overloading, but instead are lab-style instrumentsrequiring careful and regular calibration. Such current dust monitorstend to fail when exposed to a high dust concentration in a short periodof time. The dust monitor 600 disclosed herein overcomes the aboveproblems. In particular, the dust monitor 600 is configured to bemounted inside the mixing plenum 22 within the duct work of the HVACsystem as shown in FIG. 55 . This mounting location allows monitoring ofthe quality of air at the head zone of the cab operator. The mountinglocation also ensures the accuracy of the dust readings and thelongevity of the dust monitor 600. As seen in FIG. 55 , the cab has aninternal environment 30 in which the cab operator sits. Intake air issent from the precleaner 1 to the mixing plenum 22 of the HVAC system,then through the evaporator core 27, then through the fans 23 and intothe cab internal environment 30. The air then becomes recirculation air26 which flows around the operator and again into the mixing plenum 22through the vent 24. The dust monitor 600 is advantageously mounted inthe mixing plenum 22 because the mixing plenum is the cleanest locationin the cab. Moreover, the mounting location ensures that any breaches infresh or recirculation filters and/or the intake air system will beimmediately identified by the dust monitor 600 due to the increased dustreadings, thereby providing real-time data and notification of systemdegradation. The dust monitor 600 may be integrated throughcommunication with the RESPA control module 100 and the advisor module300, thereby providing robust and timely gravimetric dust monitoringwithin the same compact, proactive, comprehensive cab air qualitysystem.

The advisor module 300 may be configured to notify the appropriateparties as to alarm conditions in the cab by one or more of thefollowing notification means: sending a notification (e.g., by textmessage or email), activating an audible, visual or haptic alarm on theadvisor module 300, and activating an alarm light and/or an audiblealarm signal on top of the cab. Other notification means are alsoconceivable. These notifications may be performed by the advisor module300 simultaneously with the monitoring and control of air in the cabdiscussed above.

The advisor module 300 may automatically and autonomously maintain safeand consistent pressure and CO₂ levels within the cab by receiving thedata from the sensors and automatically controlling the air environmentwithin the cab based on the data from the sensors.

Traditional air precleaner housings absorb heat which is passeddownstream. The embodiments disclosed herein can reduce heattransmission by utilizing the swirling tornadic airflow within theprecleaner housing 11 to move the heated air, which comes off of theprecleaner housing wall, out of the precleaner housing 11 via theejection port(s) 5 on the filter cap. This unique feature performs twoimportant functions: it removes particles from the airflow ejecting themback into the environment, and it simultaneously removes heat from theprecleaner housing 11. The net result is that the air going into theengine is much closer to the ambient air temperature.

The advisor module 300 may also provide important testing and validationfunctions. The advisor module 300 can perform continuous, real-time,in-use testing of various parameters including the airflow through thesystem, the filter load and filter life, self-cleaning attributes of thefilter 7, the types and quantities of gases passing through the system,the temperature differential of the ambient air and the system outletair, and performance of the motor in the precleaner 1. The advisormodule 300 can further test other parameters related to the air qualitywithin the cab and the devices which affect the air quality.

(5) Description of Monitoring and Control Processes

At the outset, when the air quality monitoring and control system isbeing established, with the filter ID ring 200 attached (e.g., glued) tothe air filter, the air filter may be placed inside the precleanerhousing such that the filter ID ring 200 is adjacent the RESPA controlmodule 100 which is pre-installed between two stationary vanes 13 of theair precleaner 1. The RESPA control module 100 and the filter ID ring200 will then automatically sync with each other using the RCM antennaboard 118 as discussed above. The RESPA control module 100 will alsoautomatically sync with the advisor module 300.

Upon automatically syncing with the filter ID ring 200, the RESPAcontrol module 100 may read the information pre-logged into the filterID ring 200 and relay this information to the advisor module 300. Asdiscussed above, this information may include the usage of the airfilter 7, based on which the RESPA control module 100 and/or the advisormodule 300 may set a clock for determining expiration of the life of theair filter 7. In the absence of detecting a filter ID ring 200, thesystem can output a warning and/or shut down.

During operation within an active cab, the advisor module 300 maycontinuously monitor all parameters related to the environment withinthe cab, including pressurization and gas concentration, using the datawhich the advisor module 300 automatically receives from the varioussensors of the system and automatically analyzes.

The advisor module 300 may then automatically take action to control thecab environment. For example, if the advisor module 300 determines thatthe pressurization state or the concentration of a certain gas (e.g.,CO₂) inside the cab is not optimal, the advisor module 300 may controlthe airflow control valve 500 to release air from the cab. The advisormodule 300 may also issue a command to the RESPA control module 100 tochange the speed of the brushless fan motor 28 of the air precleaner 1.In this manner, the advisor module 300 is configured to constantlymonitor and adjust the cab environment to provide an optimal and safeenvironment for the cab operator.

On the other hand, if the advisor module 300 determines that theatmosphere outside of the cab is dangerous or otherwise problematic, theadvisor module 300 may control the airflow control valve 500 and the airprecleaner 1 (by way of the RESPA control module 100) to prevent outsideair from coming into the cab.

The advisor module 300 may also emit various forms of alarms (audible,visual, haptic) indicative of harmful gas concentration, expiration offilter life, and other notifications which should be provided to theoperator, owner and/or manager of the cab.

(6) Advantageous Effects

The air quality monitoring and control system according to the exemplaryembodiments discussed above provides numerous advantages, including butnot limited to the following.

Based on the communication between the RESPA control module 100, thefilter ID ring 200, the advisor module 300, and the other sensors of thesystem, the system provides continuous real-time monitoring of the cabenvironment. As a result, the system promotes the health and safety ofthe operator as well as the health of the surrounding environment.

The air quality monitoring and control system continuously andautomatically maintains the desired environment within the cab byanalyzing the data from the various sensors and automatically adjustingthe devices of the system to modify the cab environment when necessary.As a result, it is not necessary for the operator or other party toactively monitor and adjust the environment.

The advisor module 300 provides continuous data output and notificationto the operator and/or an external manager so that all parties involvedmay be notified of the status of the cab environment. Thus, the flow ofinformation is more rapid and seamless, and it is not necessary for theoperator or manager to examine and try to determine the status of thecab environment.

By interacting with the RESPA control module 100 and the other sensors,the advisor module 300 is able to control airflow, air quality, airtemperature, pressure drop on the filter 7, temperature differentialbetween outside and inside the air precleaner 1, filter life, and otherparameters to ensure that the desired cab environment is achieved andmaintained. This control by the advisor module 300 of the engine intakesystem also results in improved engine performance and fuel economy.

As needed, the advisor module 300 may control the airflow control valve500 and the fan motor 28 of the air precleaner 1 to seal and purge theinternal cab environment, stabilize pressure in the cab, and maintainappropriate gas concentrations, thereby ensuring the health and safetyof the operator.

The RESPA control module 100 continuously measures and reports thepressure and other parameters of three distinct airflows within the airprecleaner 1. Based on these different measurements, the advisor module300 is able to better detect and control the cab environment.

Integrated accelerometers provided to the sensors of both the RESPAcontrol module 100 and the advisor module 300 allow the application ofalgorithms which allow the RESPA control module 100 and the advisormodule 300 to function accurately in high vibration environments.Therefore, the deterioration of measurement and sensory data due to highvibration environments can be suppressed.

Based on the readings from the sensors, the motor control module 40 willturn off the fan motor 28 or adjust the speed of the fan motor 28 toincrease pressure or overcome a pressure drop on the filter 7. Thus,like the advisor module 300, the RESPA control module 100 automaticallyresponds to unfavorable environmental conditions, taking steps to returnthe cab to the desired environment.

When programmed operating parameters are violated, the RESPA controlmodule 100 may cause an alarm message to be sent to the advisor module300, or the advisor module 300 may make the determination to output analarm. As such, the operator and other parties involved can beautomatically notified of problems and dangers associated with the cabenvironment. These notifications may be performed by the advisor module300 simultaneously with the monitoring and control of air in the cab.

The RESPA control module 100 controls the RCM antenna board 118 tobroadcast an electrical field inside the precleaner housing 11. Thiselectrical field provides power to the filter ID ring 200 and creates atwo-way communication channel between the RESPA control module 100 andthe filter ID ring 200, allowing for continuous communication betweenthe RESPA control module 100 and the filter ID ring 200. Accordingly, noadditional power source is necessary for the filter ID ring 200, and noadditional communication means is necessary between the RESPA controlmodule 100 and the filter ID ring 200.

Currently, radial filter configurations allow for a filter to be placedin a precleaner housing in any orientation from 0 to 360 degrees.However, current RFID technologies require that the tag reader be placedwithin proximity of the RFID tag of the filter, and further requiresthat the RFID tag receive electrical power. This presents the problemthat, when the filter is placed in certain orientations within theprecleaner housing, the tag reader may not be able to read the RFID tag,and furthermore the RFID tag cannot be plugged into a power source. TheRESPA control module 100 and filter ID ring 200 disclosed hereinovercome these problems by ensuring communication between the RESPAcontrol module 100 and filter ID ring 200 regardless of the filterorientation within the precleaner housing 11. Moreover, the electricalfield broadcast by the RCM antenna board 118 of the RESPA control module100 energizes the microchip of the filter ID ring 200, thereby removingthe need for the filter ID ring 200 to be plugged into a power source.

An additional problem presented by current filter technologies is thatfilters typically have a metal protective screen and/or other metalcontent which effectively acts as a Faraday cage, obstructing thelow-power RFID signal and rendering the RFID tag inaccessible to the tagreader. The RESPA control module 100 and filter ID ring 200 disclosedherein overcome this problem by having a specific orientation andposition relative to each other within the precleaner housing 11,ensuring consistent and efficient communication via the antenna wire 124and the antenna wire 201 using the electrical field broadcast by the RCMantenna board 118. This communication is thus not obstructed by anyelement acting as a Faraday cage.

The RESPA control module 100 continuously logs data to the filter IDring 200, maintaining a constantly updated history of filter usage. Thisconstant, real-time logging of data by the RESPA control module 100 inthe filter ID ring 200, in combination with the data prestored in thefilter ID ring 200 at the point of manufacture, will ensure that thefilter 7 is not used beyond its predetermined life. Even if moved fromone vehicle to another, a tampered-with or previously-used filter can beidentified, and its use can be restricted or prevented.

Both the advisor module 300 and the RESPA control module 100 are able tocommunicate with up to 255 sensors simultaneously. As a result, theadvisor module 300 is able to receive and automatically analyze varioussensory data indicative of various parameters inside and outside thecab, thereby improving the determinations made by the advisor module 300and the actions taken by the advisor module 300 to ensure optimal cabenvironment.

The advisor module 300 is configured to automatically sync with nearbysensors and use their data to automatically implement changes to theoperator environment. Thus, the disclosed system offers an immediateresponse to potential threats within the cab environment.

The advisor module 300 may provide the display screen 308 on which datasuch as filter type, filter hours used, pressure differential, CO₂concentration, and other parameters are displayed in real time. As aresult, the operator is able to better understand and analyze the cabenvironment.

The advisor module 300 may use the sensors to monitor within the cab theCO₂ concentrations, respirable dust concentrations, fresh air intake,cab air leakage, and poisonous gas concentrations. Then, in response,the advisor module 300 can stop all air from entering the cab and fillthe cab with clean air free of poisonous gas. Thus, the advisor module300 automatically and autonomously maintains safe and consistentpressure and CO₂ levels within the cab by receiving the data from thesensors and automatically controlling the air environment within the cabbased on the data from the sensors.

Important testing and validation functions are also performed by theadvisor module 300. Continuous, real-time, in-use testing of variousparameters including the airflow through the system, the filter load andfilter life, self-cleaning attributes of the filter 7, the types andquantities of gases passing through the system, the temperaturedifferential of the ambient air and the system outlet air, andperformance of the motor 28 in the air precleaner 1 improves themonitoring of the cab environment and the ability for the operator andothers to make improvements and modifications to the environment or thecab itself.

The disclosed air quality monitoring and control system comprehensivelyprotects the operator from potential threats to air quality within thecab.

Exemplary embodiments of the present invention have been describedabove. It should be noted that the above exemplary embodiments aremerely examples and the present invention is not limited to the detailedembodiments. It should be understood that various changes andmodifications to the embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present disclosureand without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by thisdisclosure.

What is claimed is:
 1. An air quality system for a cabin, the airquality system comprising: an air precleaner having a precleaner housingand a filter disposed inside the precleaner housing; a filteridentification component positioned within the precleaner housing at afirst position, the filter identification component being mounted on thefilter; a control module positioned within the precleaner housing at asecond position and being configured to: emit an electrical field; andcommunicate with the filter identification component via the emittedelectrical field; an advisor module disposed outside of the precleanerhousing and configured to communicate with the control module to obtainfrom the control module both control module data and filteridentification component data; and a dust monitor disposed in the cabin,wherein the advisor module is configured to communicate with the dustmonitor to receive a dust measurement.
 2. The air quality systemaccording to claim 1, wherein: the control module has a first antenna;the filter identification component has a second antenna; the controlmodule emits the electrical field via the first antenna; and the controlmodule communicates with the filter identification component byexchanging data between the first and second antennas.
 3. The airquality system according to claim 2, wherein: the first antenna isdisposed at a third position different from the second position.
 4. Theair quality system according to claim 2, wherein: the second antenna istuned to a frequency of the first antenna.
 5. The air quality systemaccording to claim 1, further comprising: a plurality of sensors, thecontrol module receiving and analyzing data from the plurality ofsensors.
 6. The air quality system according to claim 1, wherein: thecontrol module comprises: a module housing; a plurality of sensors, theplurality of sensors being housed within the module housing, theplurality of sensors being configured to measure at least one ofpressure, temperature, and humidity of at least one of ambient airoutside the precleaner housing, intake air inside the precleaner housingupstream of the filter, and outlet air at an outlet of the precleanerhousing downstream of the filter; and a first antenna, the first antennabeing disposed outside of the module housing.
 7. The air quality systemaccording to claim 6, wherein: the module housing includes a pluralityof compartments, each of the compartments housing a respective one ofthe plurality of sensors.
 8. The air quality system according to claim7, wherein: a first sensor of the plurality of sensors is disposed in afirst compartment of the plurality of compartments; the module housinghas a first hole communicating with the first compartment; and a firsttube is disposed within the first hole to communicate between the firstsensor and one of the ambient air and the outlet air.
 9. The air qualitysystem according to claim 6, wherein: the filter identificationcomponent includes a second antenna, a microchip, and one or morecapacitors; and the control module: emits the electrical field via thefirst antenna; and communicates with the filter identification componentby exchanging data between the first and second antennas.
 10. The airquality system according to claim 9, wherein: the data is transmittedfrom the control module to the filter identification component and isrecorded in the filter identification component.
 11. The air qualitysystem according to claim 10, wherein: the data includes filter dataindicating usage of the filter and identification of the filter, and thefilter data is recorded in the filter identification component.
 12. Theair quality system according to claim 9, wherein: the data istransmitted from the filter identification component to the controlmodule; and the control module outputs the data to one or more externaldevices.
 13. The air quality system according to claim 8, wherein: theelectrical field emitted by the first antenna provides electric power tothe filter identification component.
 14. The air quality systemaccording to claim 1, wherein: the control module continuously reads andwrites data from and to the filter identification component via theelectrical field.
 15. The air quality system according to claim 1,wherein: the advisor module includes a plurality of sensors configuredto measure at least one of gas concentration and pressure.
 16. The airquality system according to claim 1, further comprising: an airflowcontrol valve configured to control airflow into and/or out of the airquality system, wherein the advisor module is configured to control theairflow control valve based on an airflow measurement transmitted to theadvisor module from the control module, and the advisor module isconfigured to control the airflow control valve based on the dustmeasurement.
 17. The air quality system according to claim 16, furthercomprising: a pressure sensor configured to sense pressure; wherein theadvisor module is configured to: communicate with the pressure sensor toobtain pressure data; and control the airflow control valve based on thepressure data transmitted to the advisor module from the pressuresensor.
 18. An air quality system monitoring method for a cabin, themethod comprising: providing an air precleaner outside a cab operated byan operator, the air precleaner having a precleaner housing and a filterdisposed inside the precleaner housing; providing a filteridentification component positioned within the precleaner housing at afirst position, the filter identification component being mounted on thefilter; providing a control module positioned within the precleanerhousing at a second position; providing, by the control module, anelectrical field emitted within the precleaner housing, the controlmodule communicating with the filter identification component via theemitted electrical field; providing an advisor module disposed outsideof the precleaner housing, the advisor module being configured tocommunicate with the control module to obtain from the control moduleboth control module data and filter identification component data;providing a dust monitor disposed in the cabin, wherein the advisormodule is configured to communicate with the dust monitor to receive adust measurement; and adjusting the air quality system based on thecontrol module data and the filter identification component data.